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Summary of Contents for Bulldog Security DC6000
- Page 1 DC Series Electric Winches Instruction Manual To prevent SERIOUS INJURY, DEATH and PROPERTY DAMAGE, you should read, understand and follow the warnings and instructions in this manual. Keep for future reference.
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Page 2: Table Of Contents
Read, Understand, Follow and Save These Instructions • Read, understand and follow all of these instructions and warnings before installing and using this product. • Install and use this product only as specified in these instructions. • Improper installation or use of this product may result in property damage, serious injury, and/or death. • Never allow installation or use of this product by anyone without providing them with these instruc- tions. • You must read, understand and follow all instructions and warnings for any product(s) to which this product is used in conjunction with or installed. • Save these instructions with the product for use as a reference for any future installation and use of the product. Throughout this manual WARNING, CAUTION, NOTICE and the SAFETY ALERT SYMBOL will be used. The safety alert symbol alerts you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING CAUTION NOTICE... -
Page 3: Important Safety Messages
Important Safety Messages Before First Operation opening has increased, or whose tip is bent or twisted. • Purchaser/owner must ensure that • Keep • ALWAYS use a hook with a latch. product is installed according to clear of winch, rope, hook, and these instructions. Purchaser/own- fairlead while operating. • NEVER hook back on rope. er must not alter or modify product. • Never use winch rope for towing. • The winch is not to be • NEVER use excessive effort to free • Understand your winch and used to lift, support or otherwise spool winch rope. its instructions. transport personnel. • ALWAYS take time to use appropri- • Never exceed maximum rated ate rigging techniques for a winch capacity. Refer to stamped • ALWAYS be aware of pull. -
Page 4: Know Your Winch
Know Your Winch Figure 1 - Winch Components Pendant Remote Control Socket Clutch T-Handle Winch Drum Contactor Control Box Planetary Motor Gear Box Roller Fairlead Pendant Remote Control (with Mounting Hardware) 2 Gauge Hose Clamps Battery Lead Mounting Footprint Hand Saver Winch Mounting Template Cable Strap... -
Page 5: Features And Ratings
Features and Ratings Load Rating Load and speed varies according to how much wire/synthetic rope is on the drum. The first layer of rope on the drum delivers the slowest speed and the maximum load. A full drum delivers the maximum speed and the minimum load. For this reason, all utility duty winches are rated at their first layer capacities. Table 1 - Winch Capacity DC6000 DC9000 DC12000L Rope Capacity Length of Rope Capacity Length of Rope Capacity Length of Layer Rope on Layer Rope on Layer Rope on Drum Drum Drum 12.5 ft./... - Page 6 Features and Ratings Table 2 - Winch Specifications Powered DC6000 DC9000 DC12000L DC12000 DC15000 DC18000 Winches Wire rope 5/16” x 80’ 3/8” x 82’ 3/8” x 82’ 3/8” x125’ 7/16” x 90’ 1/2” x 82’ A7 x 19 A7 x 19 A7 x 19 A7 x 19 6 x 29-IWRC 6 x 29-IWRC Aircraft Aircraft Aircraft Aircraft Cable Cable Cable Cable Brake Patented cone brake holds full load Clutch (free- Lift and Turn “T” handle...
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Page 7: Installation Instructions
ALWAYS use class 8.8 metric (grade 5) or better hardware. NEVER weld mounting bolts. ALWAYS choose the proper bolt length for your application. ALWAYS confirm required bolt length to ensure proper thread engagement. Table 4 - Mounting Torque Requirements Powered DC6000 DC9000 DC12000L DC12000 DC15000 DC18000... - Page 8 Figure 2 - Mounting Hole Templates and minimum surface areas Templates are not to scale. Remember that all winches do not mount in the same orientation. Dashed rectangle represents the cable access hole for foot forward mounting. DC6000 DC9000 & DC12000L Minimum Minimum Mounting Surface Mounting Surface DC12000, DC15000 &...
- Page 9 The mounting surface must be equal to or greater than the footprint of the winch frame. Only the mounting orientations in Table 5 are permissable for safe winching operation. All others are improper and inappropriate and will void your warranty. Table 5 - Mounting Position Specifications Mounting Position Repositioning Electric Winch Model Foot Down Foot Forward Foot Down Foot Forward DC6000 90˚ DC9000 40˚ 90˚ DC12000L 40˚ 90˚ DC12000 & DC15000 36˚...
- Page 10 Installation Instructions 1.4 Install the Winch 1. Set flanged nuts into pockets of winch feet. 2. Make sure the motor, drum and gearbox housing are aligned correctly 3. Set winch in mounting location. Confirm required bolt length. 4. Install bolts and tighten to torque specified in Table 4, Page 7. Figure 7 - Installation 1.4.1 Install the Winch fairlead NOTICE The fairlead does not mount directly to the winch.
- Page 11 Installation Instructions It may be necessary to rotate the motor or clutch. This will depend on the mounting position or variables that restrict access to the motor connections or the clutch handle. 1.5 Motor Repositioning Figure 8 - Motor Position Rotated By 90° To change the motor mounting orientation use an 11 mm wrench and remove the 2 Remove these screws. Hold the motor and pull back about screws to rotate motor a 1/4” and rotate the motor by 90 degree increments to the required position. Reinstall the two screws and torque to 10 ft.-lbs. See Figure 8. 1.5.1 Clutch Repositioning Change the position of the Free-Spool T-handle according to the following steps. Loosen and release the bolts on the brake rear cover. Rotate the gearbox by proper angle increments. See Figure 9. Re-assembly the gearbox and rear brake cover. Torque screws to 5 ft.-lbs. Figure 9 - T-Handle Cluth Postion & Rotation Clutch Handle Remove these...
- Page 12 Installation Instructions 1.6 Install the Rope WARNING ALWAYS complete the winch installation and hook attachment before installing the wiring. ALWAYS pre-stretch rope and re-spool under load before use. Tightly wound rope reduces chances of “binding”, which can damage the rope. A minimum of five (5) wraps of steel wire rope and a minimum of ten (10) wraps of synthetic rope around the drum is necessary to support the rated load.
- Page 13 Installation Instructions 1.7.1 Install the Wiring WARNING BEFORE installing the winch, make sure all electrical parts are corrosion free. ALWAYS place the supplied terminal boots on wires and terminals as directed by the installation instructions. NEVER lean over battery while making connections. NEVER route electrical cables over battery terminals.
- Page 14 Installation Instructions 1.7.4 System Check Upon completion of installation, check winch for proper operation. The voltage drop for the winch motor must not exceed 10% of the nominal voltage of 12/24 DC. Figure 15 - DC9000, DC12000L, DC12000, DC15000, & DC18000 Wiring Diagram Figure 16 - DC6000 Wiring Diagram 1.7.5 Sealed Reversing Contactor Installation WARNING 1. Disconnect the power from your winch prior to performing any maintenance or otherwise servicing your winch. 2. Remove the control box from its mounts. 3. Remove the screws from either side of the control box and remove the cover. 4. Take a picture of the contactor and the wire placement. Disconnect the wires from the contactor. 5. Remove the contactor from the control box.
- Page 15 Installation Instructions 1.7.5 Sealed Reversing Contactor Installation Continued • Sealed reversing contactor designed to control Figure 17 - Sealed Reverse Contactor direct current motors as used on winches, cranes, vehicles, etc. • IP66 rating per IEC60529 (suitable for submersible purpose) • Silver alloy contact material. • Mono-block constructions is compact in size and light weight Performance Data Thermal current rating (100%): 75 Amperes Intermittent current rating: 5% Duty ....300 Amperes 30% Duty .
- Page 16 Installation Instructions 1.8.2 Wireless Remote and Transmitter Installation 1. Connect The Wiring Figure 21 - Connections Connect the Switch cord W/3 or 6 Pin Fuse plugs to the socket on the control pack. Connect the Red wire to the positive (+) terminal of the battery. Black Connect the Black wire to the negative (-) terminal of the battery. Figure 22 - Mounting 2. Mount the Receiver The receiver should be mounted in a clear and dry location. Mount on a flat surface with at least 2 fasteners (not included) through the 7 mm mounting holes on each side of the receiver. Minimum of one mounting fastener each side 1.8.3 Wireless Remote and Transmitter Installation 1.
- Page 17 Installation Instructions 1.8.3 Wireless Remote and Transmitter Installation Continued 3. Stop Figure 25 - Resting a. T he system will automatically shut down the transmitter if not activated for 5 minutes. b. P ress and hold the Power Button for 5 sec- onds to shut down the transmitter. Programming Indicator Button 4. Reset a. Press and hold the Programming Button for 5 seconds until the Red indicator illuminates. b. Press the Power Button on the transmitter for 5 seconds until the Green indicator lights up. c. P ress the In or Out button on the transmitter until the Red indicator light on the receiver turns off. d. Reset is now completed. Please note only one remote transmitter can be reset for each receiver. 5. Notes a. The wireless remote control and wired remote can be exchanged for activating the winch or jack. b. B linking Green LED light shows the transmitter battery is low, the battery should be replaced immediately.
- Page 18 Torque the cable tensioner Install the four button head mounting plate bolts cap screws and torque to according to Table 6 20 ft.-lbs Table 6 - Cable Tensioner Mounting Torque Requirements Powered DC6000 DC9000 DC12000L DC12000 DC15000 DC18000 Winches Tie Rod...
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Page 19: Operation Instructions
Operation Instructions WARNING ALWAYS use supplied hand saver cable strap whenever spooling winch rope in or out, during installation or operation to avoid injury to hands and fingers. 2.1 Spooling in under Load WARNING NEVER exceed winch’s rated line pull. Power-in the winch rope evenly and tightly on the drum. This prevents the outer winch wraps from sinking into the inner wraps, binding and damaging the winch rope. - Page 20 Operation Instructions 2.5 for first Time operation 2.5.1 Handheld Pendant Control Figure 31 - Connect Remote Industrial grade and waterproof remote. DC12000, DC15000 and DC18000 winches includes LED overheating indicator. 2.5.2 Connect the remote control Always keep the remote control wire clear of the winch, wire/synthetic rope and roller/hawse fairlead. Figure 31. Figure 32 - Cable Button CAUTION Cable-Out Cable-In DO NOT leave the pendant control plugged into the winch when not in use.
- Page 21 Operation Instructions 2.7 Winching Principles 2.7.1 Calculating fleet Angle Figure 35 - Fleet Angle To obtain the best wire/synthetic rope service, the direction of pull will be on a horizontal within ±15 degrees and perpendicular to the centerline of the winch drum within ±5 degrees. Short pulls of up to 45 degrees laterally are acceptable; however without maintaining the proper fleet angle; the rope will pile onto one side of the rope drum and possibly do damage to the rope or winch. Re-spool your winch as required. Figure 35. Roller Fairlead 2.7.2 Recovery Damper Figure 36 - Recovery Damper A recovery damper is a safety device designed to help reduce the possibility of injury or property damage in the event of a wire/synthetic rope failure. Place in the middle third of a live rope. Figure 36. 2.7.3 Snatch Block An important aid to successful winching is the Figure37 - Snatch Block use of snatch block, which can be used to increase the pulling power of a winch or change the direction of a pull.
- Page 22 Operation Instructions 2.8 Tips for Prolonging The Life Of Synthetic Rope • Check the rope for damage or wear before each use. • Abrasion can damage or weaken your synthetic rope, protect your rope from rubbing against sharp objects. • An aluminum hawse fairlead is recommended because it has no sharp edges and resists damage more easily than a roller fairlead. • Keep your synthetic rope clean and dry. To clean it, spool out the rope, rinse it with a hose, and let it dry completely before re-spooling. WARNING Do not use the winch as a lifting device or a hoist for vertical lifting. CAUTION The “Power-Out” function should be used for relieving tension on the rope, not for extended distances.
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Page 23: Maintenance
Maintenance 3.1 Wire Rope Replacement 1. Disengage the clutch T-handle. 2. Un-spool the entire rope, and remove it from the drum. 3. Place the replacement rope through the roller fairlead opening, pass around the drum per Table 5 on Page 9 and insert it into the hole on the drum core. Tighten the set-screw downwards to secure the wire rope. 4. A minimum of five (5) wraps of wire rope and ten (10) wraps of synthetic rope around the drum is neces- sary to support the rated load. Figure 38 - Wire Rope Replacement Lift and Engaged turn to disengage 3.2 Synthetic Rope Replacement 1. Disengage the clutch T-handle, remove existing rope and replace hawse fairlead if necessary. 2. Un-spool the rope from the drum. Remove the set-screw from the drum. 3. Cut the end of the rope at 45° and apply 2-3 wraps of electrical tape to hold the cut strands in place. This will ease assembly. 4. Thread rope through a hawse fairlead and around the drum per Table 5 on Page 9, insert the rope through the hole on the drum with 6” – 8” to spare. 5. Place rope across the drum and tape the end down to hold it in place. See Figure 39 Lightly tighten the set-screw to squeeze the rope, do not over tighten. 6. A minimum of ten (10) wraps of rope around the drum is necessary to support the rated load. Figure 39 - Synthetic Rope Replacement Tape Figure 40 - Mixed Winding • Check the wire/synthetic rope. - Page 24 Figure 41 - Brake Adjustment 3.4 Lubrication All moving parts in the winch are permanently lubricated at the time of assembly. Under normal con- ditions factory lubrication will suffice. If re-lubrication of gear box is necessary after repair or disas- sembly use Shell EP2 or equivalent grease. Regularly lubricate Clutch T-handle with light oil. Never lubricate the brake system. 3.5 Tie Rod Replacement Table 7 - Tie Rod Mounting Torque Requirements 1. Disconnect power to your winch. 2. Loosen and remove the tie rod bolts and remove the Powered DC6000, DC12000, tie rods. Winches DC9000, DC15000, 3. Replace the tie rods and tie rod bolts. DC12000L DC18000 4. Using an adjustable wrench to hold the flat spots on the tie rod; torque the tie rod bolts according to the Tie Rod...
- Page 25 Troubleshooting Table 8 - Troubleshooting Symptom Possible Cause Remedy Cut circuit Check battery lead Weak battery Recharge or replace battery, 650CCA Damaged over-load protector(option) Replace over-load protector(option) Bad connection of wiring Reconnect tightly Winch will not operate Damaged contactor Replace contactor Cut circuit on switch Replace switch Damaged motor or carbon brush.
- Page 26 Checklist Table 9 - Checklist Before After Every First EVERY 90 Days Operation Read, understand and follow the warnings and instructions in this manual. Check all fasteners and verify they are at the proper torque. Replace fasteners as needed. Check wiring is correct and the connections are tight Check there are no bare or exposed wires, terminals, or damage to the cables...
- Page 27 Legal Warnings Mark Warning This is a Class B product, in a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate measures. Standard compliance of EC Directives The EC directive includes the following individual directives Machinery Directive 2006/42/EC It applies to independently functional machinery or the interlinking machines to form entire systems. The complete machine and plant must always fulfill the directive. Electromagnetic Compatibility Directive (EMC) 2004/108/EC It applies to most electrical and electronic apparatus, that is, finished products and systems that include electrical and electronic equipment to ensure that the electromagnetic disturbance generated by apparatus...
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